SPECIFICATIONS

CADWELD PLUS EXOTHERMIC

WELDING CONNECTION SYSTEM

1. SUMMARY

This specification covers the CADWELD PLUS exothermic welding system for use in making
electrical connections. The CADWELD PLUS system supplied under this specification shall include
weld metal, molds, electronic ignitors (Control Unit), tools and accessories as required.

2. SYSTEM APPLICATION

The CADWELD PLUS exothermic welding system is used for in making electrical connections of
copper to copper, copper to steel or copper to cast iron or copper to brass/bronze for grounding and
cathodic applications.

CADWELD connections shall be suitable for exposure to the elements of direct burial in earth or
concrete without degradation over the lifetime of the grounding system.

3. REFERENCES

a. ANSI/IEEE Std. 80 IEEE Guide for Safety in AC Substation Grounding

b. IEEE Standard 837 IEEE Standard for Qualifying Permanent Connections Used in Substation
Grounding
c. NFPA 70 National Electrical Code
d. ANSI / UL 467 Grounding and Bonding Equipment
e. UL 506 Specialty Transformers
f. EEC EN61000-6-2 Electromagnetic Compatibility (EMC)
g. EEC EN55011 Limits & Methods of Measurement of Radio Disturbance Characteristics of
Industrial, Scientific & Medical (ISM) Radio Frequency Equipment

4. SAFETY AGENCY APPROVALS

a. CADWELD Exothermic Connection System

The exothermic welding system supplied under this specification must be Listed by Underwriters
Laboratories to ANSI / UL 467 Grounding and Bonding Equipment.

b. Electronic Ignitor (Control Unit)

The electronic ignitor must be approved the Ignition Transformer section of UL 506 Specialty
Transformers.

34600 Solon Road Solon, OH 44139 ERICO, Inc.

(440) 248-0100 Rev. 1
12/09/03
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5. INDEPENDENT TESTING

a. CADWELD Exothermic Connection System

The CADWELD PLUS exothermic welding system furnished under this specification shall meet
the applicable requirements of IEEE Std. 80 and IEEE Std. 837. Independent test data showing
conformance to shall be readily available.

b. Electronic Ignitor (Control Unit)

The electronic ignitor must meet applicable requirements for electromagnetic compatibility. An
independent test report including results of radiated emission, electrostatic discharge and radiated
immunity shall be readily available.

6. MATERIAL

a. Molds

Molds shall be made from a synthetic graphite material capable of withstanding high
temperatures that are capable of providing an average life of not less than fifty (50) separate
exothermic welds.

b. Weld Metal

Weld metal used for grounding connections shall contain copper oxide, aluminum and not less
than 3% tin as the wetting agent.

Weld metal used for cathodic connections shall not contain tin, but shall contain vanadium.

7. ELECTRONIC IGNITOR

a. Physical

The electronic ignitor case shall be constructed with a UL 94V0 rated PC/ABS alloy with a
durable polycarbonate overlay to protect the LED and switch. The pushbutton shall be a
membrane momentary switch with tactile feel. The LED indicator shall be a high intensity for
viewing in sunlight

The leads shall be field replaceable, 18 AWG, 142-strand CU duplex, individually insulated with
PVC and fiberglass braid with high temperature silicon outer jacket.

b. Environmental

The operating temperature of the electronic ignitor shall be 0F to 120F (-17.8C to 48.9C)
and the storage temperature shall be -40F to 160F (-40C to 71.1C).

34600 Solon Road Solon, OH 44139 ERICO, Inc.

(440) 248-0100 Rev. 1
12/09/03
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 The electronic ignitor shall be designed to survive a 3 feet drop to concrete and shall be water
resistant due to submersion in 1" of water for 15 seconds.

c. Operating Characteristics

The unit shall be supplied with eight (8) AA alkaline cells and capable of delivering a minimum
of 600 charge cycles on one set of batteries. The unit shall have reverse voltage protection and
when stored for 5 years at room temperature with new batteries installed, shall retain at least
50% of the maximum number of shots.

The unit shall have a charge time of 5 seconds nominal, 7 seconds maximum on a new set of
batteries. At end of battery life, the unit will have a charge time of 15 seconds maximum.

The unit shall be supplied with an over-voltage safety shutdown feature. If an over-voltage is
detected, an internal circuit will latch and disable the pushbutton ON-switch, enabling internal
self-discharge, and preventing further use. Removing and replacing the batteries will reset this
latch circuit.

d. Pushbutton Operation

The pushbutton life shall be 100k cycles minimum. The unit will charge so long as user
continues to hold pushbutton down, should user release pushbutton at any time before external
discharge, unit will begin self discharge. Should user again press pushbutton, unit will resume
charging, so long as unit is not at full charge.

Upon reaching charge voltage, unit will dwell for 1 second +/-10%, so long as user continues to
hold pushbutton down continuously.

At the end of the dwell time, so long as user continues to hold pushbutton down continuously,
unit will trigger an internal self-discharge.

Following an external discharge, user must release the pushbutton for at least 1 second before the
unit will begin another charge cycle.

8. IDENTIFICATION

a. Molds

Graphite molds shall bear permanent marking indicating the name of the manufacturer, the mold
part number, the type and size of welding mixture compatible with the welding process and the
size of the cable or bus connection. Instructions detailing general safety information, connection
preparation and welding procedures shall be provided with each mold.

b. Weld Metal

Weld metal packages shall be color coded for easy identification and the weld metal
manufacturing lot number shall be laser printed with permanent ink.
34600 Solon Road Solon, OH 44139 ERICO, Inc.
(440) 248-0100 Rev. 1
12/09/03
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 Integral weld metal packages shall be identified as to the part number (size), and type of metals
to be connected or shall be marked for their intended use such as cathodic connections.

9. MANUFACTURERS QUALIFICATIONS

a. Manufacturer shall be ISO9001:2000 certified.

b. Manufacturer shall have been engaged in the design and manufacturing of exothermic systems
for at least ten (20) years.

10. QUALITY CONTROL

a. Weld Metal

Weld metal shall be controlled at the factory and subjected to routing and rigid quality control
inspection procedures.

b. Electronic Ignitor (Control Unit)

The electronic ignitor shall be marked with traceable manufacturing run number on the unit and
on the external packaging for quality control purposes.

11. PACKAGING AND SHIPPING

Weld metal shall be pre-measured, packaged and sealed in tamper-proof containers to prevent
spillage during shipping. Integral weld metal cups shall be packaged in be moisture resistant,
recyclable containers.

12. TRAINING

Use of the CADWELD PLUS exothermic connection system shall require minimal training. Factory
trained personnel shall respond to field calls quickly and provide training for construction crews on
the proper techniques for making CADWELD connections.

34600 Solon Road Solon, OH 44139 ERICO, Inc.

(440) 248-0100 Rev. 1
12/09/03
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